U.S. patent application number 10/286419 was filed with the patent office on 2004-05-06 for system for monitoring optimal equipment operating parameters.
Invention is credited to Singh, Abtar.
Application Number | 20040088069 10/286419 |
Document ID | / |
Family ID | 32175446 |
Filed Date | 2004-05-06 |
United States Patent
Application |
20040088069 |
Kind Code |
A1 |
Singh, Abtar |
May 6, 2004 |
System for monitoring optimal equipment operating parameters
Abstract
A system for monitoring equipment operating parameters of a
remote system includes a monitor that communicates with a
controller of the remote system, and at least one piece of
equipment operable within the remote system, and that communicates
with the controller. The equipment has at least one associated
operating parameter. The monitor compares a present value of the
associated operating parameter to a previous value to determine a
difference therebetween. The difference is associated with a cost,
measuring the cost of operating the equipment at the present
operating parameter.
Inventors: |
Singh, Abtar; (Kennesaw,
GA) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
32175446 |
Appl. No.: |
10/286419 |
Filed: |
October 31, 2002 |
Current U.S.
Class: |
700/108 |
Current CPC
Class: |
G06Q 50/06 20130101;
H04Q 2209/823 20130101; G05B 15/02 20130101; G05B 2219/2642
20130101; F25B 49/005 20130101; H04Q 9/00 20130101 |
Class at
Publication: |
700/108 |
International
Class: |
G06F 019/00 |
Claims
What is claimed is:
1. A set-point monitoring system in communication with a controller
of a remote system having at least one piece of equipment operating
at an associated set-point, the set-point monitoring system
comprising: a monitor in communication with the controller and the
at least one piece of equipment, said monitor monitoring a present
value of the associated set-point and compares said present value
to a previous value of said associated set-point.
2. The system of claim 1, wherein said monitor continuously
monitors the associated set-point.
3. The system of claim 1, wherein said monitor periodically
monitors the associated set-point.
4. The system of claim 1, wherein said monitor is alerted to a
change in the associated set-point.
5. The system of claim 1, wherein said previous value is a
benchmark value.
6. The system of claim 1, wherein said previous value is a
previously monitored value.
7. The system of claim 1, wherein said monitor records said present
value if different than said previous value.
8. The system of claim 1, further comprising a communication
network enabling communication between said monitor and the remote
system.
9. The system of claim 8, wherein said communication network is the
internet.
10. The system of claim 1, wherein said monitor associates a cost
based on comparing said present value to said previous value.
11. A method of monitoring optimal equipment operating parameters
of a remote system, comprising: monitoring an operating parameter
of a piece of equipment of the remote system; comparing a present
value of said operating parameter to a previous value; indicating a
change if said present value is different than said previous value;
and communicating said operating parameter, said present value to a
monitoring system.
12. The method of claim 11, further comprising accessing said
monitoring system via a communication network.
13. The method of claim 11, wherein said previous value is a
benchmark value.
14. The method of claim 11, wherein said previous value is a
previously monitored value.
15. The method of claim 11, wherein said monitor records said
present value if different than said previous value.
16. The method of claim 11, wherein said operating parameter is a
set point.
17. The method of claim 11, further comprising providing a
communication network to enable communication between said
monitoring system, and the remote system.
18. The method of claim 17, wherein said communication network is
the internet.
19. The method of claim 11, further comprising providing a
controller associated with the remote system, said controller
communicating with said monitoring system.
20. The method of claim 11, further comprising: determining a
difference between said present value and said previous value; and
associating said difference with a monetary value to indicate a
change in cost as a result of said difference.
21. A method of monitoring optimal equipment set-points of a
plurality of remote systems, comprising: monitoring set-points
associated with equipment of the plurality of remote systems;
comparing present values of said set-points to corresponding
previous values; indicating respective changes if said present
values are different than said previous values; and communicating
said present values and said previous values of said set-points to
a monitoring system.
22. The method of claim 21, further comprising accessing said
monitoring system via a communication network.
23. The method of claim 21, wherein said previous values are
benchmark values.
24. The method of claim 21, wherein said previous values are
previously monitored values.
25. The method of claim 21, wherein said monitor records said
present values if different than said previous values.
26. The method of claim 21, further comprising providing a
communication network to enable communication between said
monitoring system and the plurality of remote systems.
27. The method of claim 26, wherein said communication network is
the internet.
28. The method of claim 21, further comprising providing
controllers associated with each of the plurality of remote
systems, said controllers communicating with said monitoring
system.
29. The method of claim 21, further comprising: determining
respective differences between said present values and said
previous values; and associating said differences with monetary
values to indicate a change in costs as a result of said
differences.
30. The method of claim 29, further comprising totaling said
monetary values to determine one of an aggregate increased and
decreased cost.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to monitoring equipment
operating parameters and, more particularly, to a system for
monitoring optimal equipment parameters of equipment for
refrigeration, HVAC, lighting, anti-condensate heating, and other
systems.
BACKGROUND OF THE INVENTION
[0002] Retail outlets, particularly food retailers, require a
plurality of systems during operation. Such systems often include
refrigeration, HVAC, lighting, anti-condensate heating (ACH), and
defrost control systems. Each of these systems include associated
equipment to perform various functions. For example, refrigeration
systems include compressors, condensers, evaporators, and the like
to cool refrigeration cases to a desired temperature.
[0003] The various types of equipment include operating parameters,
or set points, at which the equipment operates. The set point
defines the operating condition of the equipment and is adjusted to
provide a desired output from the equipment. For example, a set
point of an electronic pressure regulator is adjusted to maintain a
desired pressure within an evaporator of a refrigeration system.
Because the equipment of the various systems consume power during
their operation, the amount of power consumed by a particular piece
of equipment corresponds to the set point value. Thus, if a set
point is changed, the amount of power consumed by the equipment
correspondingly changes.
[0004] Generally, a retailer configures the particular systems of
its associated retail locations to operate at an optimized level.
Thus, optimized set points are determined and set, whereby the
systems operate in a desired manner, typically efficiently.
However, set point changes can occur for various reasons, including
maintenance, cleaning, and the like. Often, the set points are not
returned to their previous levels, resulting in the systems
operating in an undesired manner or at inefficient levels.
Traditionally, it is difficult for a retailer to routinely monitor
the set points of the systems of its various retail locations. As a
result, the systems of the retail locations operating in an
undesired manner or at inefficient levels incur significant cost to
the retailer over time.
SUMMARY OF THE INVENTION
[0005] The present invention provides a method of monitoring
optimal equipment operating parameters of a remote system. The
method includes monitoring an operating parameter of a piece of
equipment of the remote system and communicating the operating
parameter to a monitoring system. A present value of the operating
parameter is compared to a previous value, and a change is
indicated if the present value is different than the previous
value.
[0006] Preferably, a difference between the present value and the
previous value is determined. The difference is associated with a
monetary value to indicate one of an increase and a decrease in
cost. Additionally, the monitoring system is accessible by a remote
user via a communication network, whereby the remote user is able
to review changes and associated costs of the operating
parameter.
[0007] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limited the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0009] FIG. 1 is a schematic illustration of a building system for
use with the method for analyzing the building system performance
according to the principles of the present invention;
[0010] FIG. 2 is a schematic illustration of an exemplary
refrigeration system according to the principles of the present
invention;
[0011] FIG. 3 is a schematic illustration of an exemplary HVAC
system according to the principles of the present invention;
[0012] FIG. 4 is a schematic illustration of an exemplary lighting
system according to the principles of the present invention;
and
[0013] FIG. 5 is a detailed schematic illustration of an exemplary
refrigeration system according to the principles of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] The present system for monitoring optimal equipment
operating parameters provides a comprehensive building system
assessment and energy management solution. The system is
particularly applicable to refrigeration, HVAC, lighting,
anti-condensate heating (ACH), and defrost control systems. As
shown in FIG. 1, an HVAC controller 1 is in communication with a
refrigeration controller 2, an ACH condensate heater controller 3,
and a lighting controller 4. These components are typically located
in a building 5. Further, the HVAC controller 1 is in communication
via communication network 6, including a modem or internet
connection, to a remote monitor 7 at a remote location 8. As shown,
the HVAC controller 1 communicates with the HVAC system, with the
refrigeration controller 2, the ACH controller 3, and the lighting
controller 4, which respectively communicate with the refrigeration
system, the anti-condensate heaters, and lighting system. Although
the HVAC controller 1 is shown as a communication gateway between
the various controllers 2, 3, 4 and the remote monitor 7, it will
be appreciated that any of the controllers 1-4 can function as a
communication gateway. Alternatively, each controller 1, 2, 3, 4
can be connected to a network backbone that has a dedicated
communication gateway (such as a personal computer, server computer
or other controller) to provide internet, modem or other remote
access. It will be appreciated that the illustration of FIG. 1 is
merely exemplary, and more or fewer building control systems may be
included.
[0015] With reference to FIG. 2, a basic refrigeration system 200
is shown. The refrigeration system 200 includes one or more
compressors 210, condensers 220 and refrigeration fixtures 230. The
condensers 220, compressors 210, and refrigeration fixtures 230
communicate with the refrigeration controller 2. Such communication
may be networked, dedicated direct connections or wireless.
[0016] Similarly with FIG. 3, an exemplary HVAC system 300 is
shown. As shown, the HVAC controller 1 communicates with a fan 310
and sensors 320, as well as a cooling apparatus 330, heating
apparatus 340 and damper 350, if appropriate. The fan 310, cooling
apparatus 330, heating apparatus 340 and damper 350 communicate
with the HVAC controller 1. Such communication may be networked,
dedicated direct connections or wireless.
[0017] FIG. 4 shows a lighting system 400. As shown, one or more
lighting fixtures 410 communicate with the lighting controller 4.
The lighting fixtures 410 are shown in various areas of the
building and its exterior, with some areas including multiple types
of fixtures while lighting fixtures for multiple areas may also be
similarly controlled. For example, FIG. 4 illustrates a sales area
420, a department area 430 and a parking lot 440. The department
area 430 includes lighting fixtures 410, as well as lighting
fixtures 410 for display cases 450 therein. The parking lot 440
includes lighting fixtures 410 as well as an exterior sign lighting
460. The various lighting fixtures 410 are in communication with
the lighting controller 4. Such communication may be networked,
dedicated direct connections or wireless.
[0018] With reference to FIG. 5, a detailed block diagram of the
exemplary refrigeration system 200 is shown. The refrigeration
system 200 includes a plurality of compressors 12 piped together
with a common suction header 14 and a discharge header 16 all
positioned within a compressor rack 18. The compressor rack 18
compresses refrigerant vapor that is delivered to an oil separator
36 from which the vapor is delivered via a first line 37 to a hot
gas defrost valve 40 and a three-way heat reclaim valve 42. The hot
gas defrost valve 40 enables hot gas to flow to an evaporator (not
shown) through liquid line solenoid valve 70 and solenoid valve 68.
The heat reclaim valve 42 enables hot gas to flow to the heat
reclaim coils 46 and to a condenser 20 where the refrigerant vapor
is liquefied at high pressure.
[0019] A second line 39 of the oil separator 36 delivers gas
through a receiver pressure valve 48 to a receiver 52. The receiver
pressure valve 48 ensures the receiver pressure does not drop below
a set value. The condenser 20 sends fluid through a condenser flood
back valve 58 to the receiver 52. The condenser flood back valve 58
restricts the flow of liquid to the receiver 52 if the condenser
pressure becomes too low. Evaporator pressure regulator (EPR)
valves 28 are mechanical control valves used to maintain a minimum
evaporator pressure in cases 22. The EPR valves 28 operate by
restricting or opening a control orifice to raise or lower the
pressure drop across the valve, thereby maintaining a steady valve
inlet (and associated evaporator pressure) even as the evaporator
load or rack suction pressure varies in response to the addition or
subtraction of compressor capacity or other factors.
[0020] A surge valve 60 enables liquid to bypass the receiver 52
when it is subcooled in the ambient. Accordingly, ambient subcooled
liquid joins liquid released from the receiver 52, and is then
delivered to a differential pressure regulator valve 62. During
defrost, the differential pressure regulator valve 62 reduces
pressure delivered to the liquid header 64. This reduced pressure
enables reverse flow through the evaporator during defrost. Liquid
flows from liquid header 64 via a first line through a liquid
branch solenoid valve 66, which restricts refrigerant to the
evaporators during defrost but enables back flow to the liquid
header 64. A second line carries liquid from the liquid header 64
to the hot gas defroster 72 where it exits to an EPR/Sorit valve
74. The EPR/Sorit valve 74 adjusts so the pressure in the
evaporator is greater than the suction header 14 to enable the
evaporator to operate at a higher pressure.
[0021] The high-pressure liquid refrigerant leaving liquid branch
solenoid valve 66 is delivered to a plurality of refrigeration
cases 22 by way of piping 24. Circuits 26 consisting of a plurality
of refrigeration cases 22 operate within a certain temperature
range. FIG. 5 illustrates four (4) circuits 26 labeled circuit A,
circuit B, circuit C and circuit D. Each circuit 26 is shown
consisting of four (4) refrigeration cases 22. However, those
skilled in the art will recognize that any number of circuits 26,
as well as any number of refrigeration cases 22 may be employed
within a circuit 26. As indicated, each circuit 26 will generally
operate within a certain temperature range. For example, circuit A
may be for frozen food, circuit B may be for dairy, circuit C may
be for meat, etc.
[0022] Because the temperature requirement is different for each
circuit 26, each circuit 26 includes a EPR valve 28 that acts to
control the evaporator pressure and, hence, the temperature of the
refrigerated space in the refrigeration cases 22. The EPR valves 28
can be electronically or mechanically controlled. Each
refrigeration case 22 also includes its own expansion valve (not
shown) that may be either a mechanical or an electronic valve for
controlling the superheat of the refrigerant. In this regard,
refrigerant is delivered by piping to the evaporator in each
refrigeration case 22. The refrigerant passes through an expansion
valve where a pressure drop causes the high pressure liquid
refrigerant to become a lower pressure combination of liquid and
vapor. As the hot air from the refrigeration case 22 moves across
the evaporator, the low pressure liquid turns into gas. This low
pressure gas is delivered to the pressure regulator 28 associated
with that particular circuit 26. At EPR valves 28, the pressure is
dropped as the gas returns to the compressor rack 18. At the
compressor rack 18, the low pressure gas is again compressed to a
high pressure gas, which is delivered to the condenser 20, which
creates a high pressure liquid to supply to the expansion valve and
start the refrigeration cycle over.
[0023] A main refrigeration controller 2 is used and configured or
programmed to control the operation of the refrigeration system
200. The refrigeration controller 2 is preferably an Einstein Area
Controller offered by CPC, Inc. of Atlanta, Ga., U.S.A., or any
other type of programmable controller which may be programmed, as
discussed herein. The refrigeration controller 2 controls the bank
of compressors 12 in the compressor rack 18 via an input/output
module 32. The input/output module 32 has relay switches to turn
the compressors 12 on and off to provide the desired suction
pressure. A separate case controller (not shown), such as a CC-100
case controller, also offered by CPC, Inc. of Atlanta, Ga., U.S.A.,
may be used to control the superheat of the refrigerant to each
refrigeration case 22 via an electronic expansion valve in each
refrigeration case 22 by way of a communication network or bus 34.
Alternatively, a mechanical expansion valve may be used in place of
the separate case controller. Should separate case controllers be
utilized, the main refrigeration controller 2 may be used to
configure each separate case controller, also via the communication
bus 34. The communication bus 34 may be a RS-485 communication bus,
a LonWorks Echelon bus or any other communication platform that
enables the main refrigeration controller 30 and the separate case
controllers to receive information from each case 22.
[0024] Each refrigeration case may have a temperature sensor 44
associated therewith, as shown for circuit B. The temperature
sensor 44 can be electronically or wirelessly connected to the
controller 2 or the expansion valve for the refrigeration case.
Each refrigeration case 22 in the circuit B may have a separate
temperature sensor 44 to take average/minimum/maximum temperatures
or a single temperature sensor 44 in one refrigeration case 22
within circuit B may be used to control each case 22 in circuit B
because all of the refrigeration cases 22 in a given circuit
operate in substantially the same temperature range. These
temperature inputs are preferably provided to the analog input
board 38, which returns the information to the main refrigeration
controller via the communication bus 34.
[0025] The particular set points of the various equipment of the
refrigeration system 200 are preferably set to optimized values to
achieve efficient operation of the refrigeration system 200. These
optimized values are benchmark values preferably determined during
a system performance analysis. Such a method is disclosed in
commonly assigned U.S. Patent Application No. 60/287,458, entitled
Building System Performance Analysis, which is expressly
incorporated herein by reference. In short, the method includes an
examination of existing system conditions and operating parameters
using a combination of remote monitoring and on-site technicians. A
series of prescribed testing and adjustment procedures are also
conducted. Through a continuous follow-up process and associated
feedback-loop activities, optimized operating parameters (i.e., set
points) of the various equipment are determined to maintain the
system in an enhanced performance state. Although the optimized
operating parameters of the refrigeration system 200 are preferably
determined implementing the method described immediately above, it
will be appreciated that other methods may be used.
[0026] While the present invention is discussed in detail below
with respect to specific components as contained in refrigeration
system 200, it will be appreciated that the present invention may
be employed with other types of systems having configurable
components to provide substantially the same results as discussed
herein. By way of example, other types of systems include, but are
not limited to HVAC, lighting, ACH, and defrost.
[0027] Initially, application-specific operating parameters, or set
points, are determined for the equipment of the refrigeration
system 200. These set points include control method (e.g.,
pressure, temperature), suction float, minimum float point, maximum
float point, suction group set point, control sensor offset,
condenser set point, and ambient sensor offset. More particularly,
the set points preferably include minimum head pressure, air-cooled
condenser fan speed, hold-back valve pressure, evaporator condenser
sump temperature, receiver pressurization valve, EPR valve
pressure, suction pressure, and discharge pressure. As discussed
above, these set points are preferably determined implementing the
system performance analysis method.
[0028] With regard to the HVAC systems 300, set points include
cooling, heating, dehumidification, cooling override, heating
override and fan override. With regard to defrost, set points
include number of defrosts per day, defrost duration, termination
type and termination temperature. For the lighting system 400, set
points include light level, on time and off time.
[0029] The monitoring method of the present invention initially
includes each controller 1, 2, 3, 4 monitoring the equipment set
points of their respective systems. It is anticipated that the
controllers 1, 2, 3, 4 either continuously monitor the set points,
periodically monitor the set points, or are alerted to a set point
change. Continuous, and alert monitoring of the set points enable
the particular controller to determine the precise time a set point
change occurred. Periodically monitoring the set points enables the
particular controller to determine a time range, within which a set
point change occurred. The remote monitor 7 periodically
communicates with the controllers 1, 2, 3, 4 through the
communication network 6 to obtain the various set point
information.
[0030] The remote monitor 7 stores the set point information in
memory for the various systems of building 5. The remote monitor 7
periodically communicates with the controllers 1, 2, 3, 4 to obtain
present set point information. The remote monitor 7 also records
the base or benchmark set points for the equipment of the various
systems. In this manner, the benchmark set point is stored for
informational purposes. The remote monitor 7 initially records the
benchmark set point as a prior set point. The remote monitor 7
compares the monitored, or present set point to the prior set point
for the individual equipment. In this manner, the remote monitor 7
determines whether a change in any of the set points has occurred.
If there is no difference between the present set point and the
prior set point, then the remote monitor 7 continues monitoring
with no other action. If there is a difference between the present
set point and the prior set point, the remote monitor 7 stores into
memory the present set point as well as the time that the set point
change occurred.
[0031] Once the set point information has been recorded into
memory, the remote monitor 7 overwrites the prior set point,
recording the present set point as the prior set point. In this
manner, the prior set point is consistently updated after a change
in set point occurs and continues to be the value compared against
to determine whether further changes in set point have
occurred.
[0032] It is also anticipated that the controllers 1, 2, 3, 4 can
continuously monitor the set point changes in their respective
systems and alert the remote monitor of a change in set point. More
specifically, the local controllers 1, 2, 3, 4 store the benchmark
set point. The controllers initially record the benchmark set point
as the prior set point. The controllers compare the monitored, or
present set point to the prior set point for the individual
equipment. In this manner, the controllers determine whether a
change in any of the set points has occurred. If there is no
difference between the present set point and the prior set point,
then the controllers continue monitoring with no other action. If
there is a difference between the present set point and the prior
set point, the controllers store into memory the present set point
as well as the time that the set point change occurred.
[0033] Once the set point information has been recorded into
memory, the controllers overwrite the prior set point, recording
the present set point as the prior set point. In this manner, the
prior set point is consistently updated after a change in set point
occurs and continues to be the value compared against to determine
whether further changes in set point have occurred.
[0034] Regardless of whether the local controllers 1, 2, 3, 4 or
the remote monitor 7 monitor the set point changes, the remote
monitor 7 inputs the set point information into a database. The
database is accessible via the communication network 6 by a remote
user 9. The database sorts the set point information such that it
is accessible by the remote user 9 in a variety of manners via a
web interface. For example, the remote user 9 may select a
particular location (e.g., building 5) to view the set point
changes, and present set point values at that particular location.
Additionally, the remote user 9 is able to view the benchmark set
points of the various equipment within a particular location, the
present set point, and the set point used prior to the benchmark
set point. Further, the remote user 9 can access a summary of the
set point changes which have occurred across all of the locations.
The various set point information is accessible for any of the
systems, including the refrigeration system 200, ACH, defrost, HVAC
300, and lighting 400 systems.
[0035] The remote monitor 7 further associates the set points and
set point changes with a cost. The set points of the various
equipment within the systems signal the equipment to operate
consuming an associated amount of power. A set point change alters
the amount of power required by a piece of equipment to operate.
Thus, a comparison of set points can indicate an increase, or
decrease in power consumption. Standardized costs are available
throughout different regions to determine a cost associated with a
particular power consumption rate. More particularly, the remote
monitor 7 is able to access a database that maintains a record of
power consumption costs for various regions, or even particular
locations. The remote monitor 7 is able to determine a rate of
power consumption for a particular piece of equipment at the
benchmark set point, and compare that to a rate of power
consumption at the present set point. If there is a difference
between the two, the remote monitor is able to associate this
difference with a cost. In this manner, the remote user 9 may
determine the effect a set point change has on the overall
operating costs of the particular system for a chosen time period
(e.g., days, weeks, years, etc.).
[0036] The description of the invention is merely exemplary in
nature and, thus, variations that do not depart from the gist of
the invention are intended to be within the scope of the invention.
Such variations are not to be regarded as a departure from the
spirit and scope of the invention.
* * * * *